Battery Substrate Support Structure for Stable 3D Particle Patterns
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Solution Overview
Problem
Existing methods for producing all-solid-state batteries with thin adhesive layers face challenges such as chipping, tearing, and pattern disorder due to adhesive layer extension and deformation, particularly in larger batteries, making it difficult to achieve stable production of secondary battery components with arbitrary three-dimensional material arrangements.
Innovation Solution
A battery substrate design that includes a first substrate with an adhesive layer and a particle layer, supported by a second substrate in at least two directions, which reduces adhesive layer extension and deformation, ensuring the particle pattern remains intact during the production process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If the thickness of the adhesive layer is reduced, then heat treatment time is shortened and thermal load on battery material is reduced, but chipping and tearing occur at the ends of the battery substrate during separation
Solution Approach 1:
A support structure is preliminarily arranged beneath the adhesive layer before the separation process. This support structure prevents the adhesive layer from deforming or tearing during separation, allowing the use of thin adhesive layers without compromising structural integrity during the separation process
Solution Approach 2:
A support structure acts as an intermediary between the adhesive layer and the underlying surface. This intermediary provides mechanical support to the thin adhesive layer during separation, preventing chipping and tearing while allowing the adhesive layer to maintain its reduced thickness
2Productivity
If the adhesive layer is made thin, then production efficiency is improved, but wrinkles and folds occur in the adhesive layer during separation and lamination
Solution Approach 1:
The support structure is preliminarily positioned to match the pattern of the adhesive layer before separation. This preliminary arrangement ensures that the thin adhesive layer maintains its flat configuration throughout the separation and lamination processes, preventing wrinkles and folds from forming
3Area of moving object
If the area of the battery substrate is increased, then battery capacity is improved, but the adhesive layer becomes more prone to deformation and bonding issues
Solution Approach 1:
The support structure is segmented to correspond to different regions of the large-area battery substrate. This segmentation allows each portion of the adhesive layer to be independently supported, preventing cumulative deformation effects that would otherwise occur in large-area substrates and maintaining pattern arrangement precision throughout the entire battery area
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The proposed substrate structure effectively prevents wrinkles and adhesions, allowing for the stable arrangement of battery material particles in a three-dimensional pattern without collapsing, even in larger batteries, thereby improving production stability and reducing costs.
Implementation Method 1
an adhesive layer (102) having one surface adhered to the first substrate (103)
Data Source
AI summary
A battery substrate applied to a secondary battery, comprising: a first substrate comprising a resin; an adhesive layer having one surface adhered to the first substrate; a particle layer comprising at least one selected from the group consisting of a solid electrolyte, an active material and a current collector material and disposed on the other surface opposite to the one surface of the adhesive layer; and a second substrate disposed in a region of the other surface where the particle layer is not disposed, wherein the second substrate is disposed so as to support a periphery of a region where the particle layer is disposed in at least two directions.